Jeep Cherokee (XJ): Removal and installation

Battery cables

Both the battery negative cable and the battery positive cable are serviced in the battery wire harness.

If either battery cable is damaged or faulty, the battery wire harness unit must be replaced.

REMOVAL

(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.

(2) Loosen the battery negative cable terminal clamp pinch-bolt hex nut.

(3) Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.

(4) Loosen the battery positive cable terminal clamp pinch-bolt hex nut.

(5) Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.

(6) Unlatch and remove the B(+) terminal stud cover from the front of the Power Distribution Center (PDC).

(7) Remove the nut that secures the battery positive cable eyelet terminal and the generator output cable eyelet terminal to the B(+) terminal stud on the PDC.

(8) Remove the battery positive cable eyelet terminal and the generator output cable eyelet terminal from the B(+) terminal stud on the PDC.

(9) Disconnect the battery wire harness connector from the headlamp and dash wire harness connector located below the front of the PDC.

(10) Remove the screw that secures the battery negative cable eyelet terminal to the inner fender shield near the battery.

(11) On LHD models with air conditioning, disconnect the compressor clutch wire harness connector from the battery wire harness connector.

(12) Unlatch and remove the cover from the generator output terminal stud housing on the back of the generator.

(13) Remove the nut that secures the generator output cable eyelet terminal to the generator output terminal stud.

(14) Remove the generator output cable eyelet terminal from the generator output terminal stud.

(15) Disconnect the battery wire harness connector from the generator field terminal connector receptacle on the back of the generator.

(16) Remove the nut that secures the battery negative cable ground eyelet terminal to the stud on the right side of the engine block.

(17) Remove the battery negative cable ground eyelet terminal from the engine block stud.

(18) On models with a 2.5L engine, remove the nut that secures the battery wire harness locator clip to the stud on the right side engine block oil pan rail below and forward of the engine oil filter adapter.

(19) On models with a 4.0L engine, remove the screw that secures the battery wire harness locator clip to the right side of the engine block between and below the right engine mount and the oil filter adapter.

(20) Remove the nut that secures the battery positive cable eyelet terminal to the B(+) terminal stud on the starter solenoid.

(21) Remove the battery positive cable eyelet terminal from the B(+) terminal stud on the starter solenoid.

(22) Disconnect the battery wire harness connector from the connector receptacle on the starter solenoid.

(23) Remove the battery wire harness from the engine compartment.

INSTALLATION

(1) Clean and inspect the battery cable terminal clamps and the battery terminal posts. Refer to Battery in the index of this service manual for the location of the proper battery cable terminal clamp and battery terminal post cleaning and inspection procedures.

(2) Position the battery wire harness into the engine compartment.

(3) Reconnect the battery wire harness connector to the connector receptacle on the starter solenoid.

(4) Install the battery positive cable eyelet terminal onto the B(+) terminal stud on the starter solenoid.

(5) Install and tighten the nut that secures the battery positive cable eyelet terminal to the B(+) terminal stud on the starter solenoid. Tighten the nut to 10 N·m (90 in. lbs.).

(6) On models with a 2.5L engine, install and tighten the nut that secures the battery wire harness locator clip to the stud on the right side engine block oil pan rail below and forward of the engine oil filter adapter. Tighten the nut to 8.4 N·m (75 in. lbs.).

(7) On models with a 4.0L engine, install and tighten the screw that secures the battery wire harness locator clip to the right side of the engine block between and below the right engine mount and the oil filter adapter. Tighten the screw to 8.4 N·m (75 in.

lbs.).

(8) Install the battery negative cable ground eyelet terminal onto the stud on the right side of the engine block.

(9) Install and tighten the nut that secures the battery negative cable ground eyelet terminal to the stud on the right side of the engine block. Tighten the nut to 15.8 N·m (140 in. lbs.).

(10) Reconnect the battery wire harness connector to the generator field terminal connector receptacle on the back of the generator.

(11) Install the generator output cable eyelet terminal onto the generator output terminal stud.

(12) Install and tighten the nut that secures the generator output cable eyelet terminal to the generator output terminal stud. Tighten the nut to 8.4 N·m (75 in. lbs.).

(13) Position the cover for the generator output terminal stud housing onto the back of the generator and snap it into place.

(14) On LHD models with air conditioning, reconnect the compressor clutch wire harness connector to the battery wire harness connector.

(15) Install and tighten the screw that secures the battery negative cable eyelet terminal to the inner fender shield near the battery. Tighten the screw to 24.8 N·m (220 in. lbs.).

(16) Reconnect the battery wire harness connector to the headlamp and dash wire harness connector located below the front of the PDC.

(17) Install the battery positive cable eyelet terminal and the generator output cable eyelet terminal onto the PDC B(+) terminal stud.

(18) Install and tighten the nut that secures the battery positive cable eyelet terminal and the generator output cable eyelet terminal to the PDC B(+) terminal stud. Tighten the nut to 10.7 N·m (95 in.

lbs.).

(19) Engage the tabs on the lower edge of the B(+) terminal stud cover in the slots on the front of the PDC housing, then engage the latch on the top of the cover with the latch tabs on the PDC housing.

(20) Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

(21) Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

(22) Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.

Battery hold downs

All of the battery hold down hardware except for the T-bolts can be serviced without removal of the battery or the battery tray. The battery tray must be removed from the vehicle to service the T-bolts. If the T-bolts require service replacement, refer to Battery Tray in the index of this service manual for the location of the proper battery tray removal and installation procedures.

REMOVAL

(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.

(2) Loosen the battery negative cable terminal clamp pinch-bolt hex nut.

(3) Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.

(4) Remove the nut with washer from the threaded end of each of the two T-bolts (Fig. 19).

(5) Remove the screw with washer that secures the end of the battery support strap with a slotted hole to the top of the upper radiator crossmember.

(6) Remove the battery support strap from the threaded end of the T-bolt nearest to the front of the vehicle.

(7) Remove the battery hold down bracket from the threaded ends of the two T-bolts and the top of the battery case.

INSTALLATION

(1) Clean and inspect the battery hold down hardware.

Refer to Battery in the index of this service manual for the location of the proper battery hold down hardware cleaning and inspection procedures.

(2) Position the battery hold down bracket onto the threaded ends of the two T-bolts and across the top of the battery case.

Fig. 19 Battery Hold Downs Remove/Install

1 - SCREW AND WASHER (1)
2 - NUT AND WASHER (2)
3 - T-BOLT (2)
4 - RETAINER (2)
5 - BATTERY TRAY
6 - UPPER RADIATOR CROSS MEMBER
7 - BRACKET
8 - STRAP

(3) Position the battery support strap with the round hole over the threaded end of the T-bolt nearest to the front of the vehicle and the slotted hole over the mounting hole in the top of the upper radiator crossmember.

(4) Install and tighten the screw with washer that secures the end of the battery support strap with a slotted hole to the top of the upper radiator crossmember.

Tighten the screw to 8.7 N·m (77 in. lbs.).

(5) Install and tighten the nut with washer onto the threaded end of each of the two T-bolts. Tighten the nuts to 2.2 N·m (20 in. lbs.).

(6) Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

Battery

REMOVAL

(1) Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off.

(2) Loosen the battery negative cable terminal clamp pinch-bolt hex nut.

(3) Disconnect the battery negative cable terminal clamp from the battery negative terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post (Fig. 20).

Fig. 20 Remove Battery Cable Terminal Clamp - Typical

1 - BATTERY
2 - BATTERY TERMINAL PULLER

(4) Loosen the battery positive cable terminal clamp pinch-bolt hex nut.

(5) Disconnect the battery positive cable terminal clamp from the battery positive terminal post. If necessary, use a battery terminal puller to remove the terminal clamp from the battery post.

(6) Remove the battery hold downs from the battery.

Refer to Battery Hold Downs in the index of this service manual for the location of the proper battery hold down removal procedures.

WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.

(7) Remove the battery and the battery thermoguard from the battery tray as a unit.

(8) Remove the battery thermoguard from the battery case. Refer to Battery Thermoguard in the index of this service manual for the location of the proper battery thermoguard removal procedures.

INSTALLATION

(1) Clean and inspect the battery. Refer to Battery in the index of this service manual for the location of the proper battery cleaning and inspection procedures.

(2) Reinstall the battery thermoguard onto the battery case. Refer to Battery Thermoguard in the index of this service manual for the location of the proper battery thermoguard installation procedures.

(3) Position the battery and the battery thermoguard onto the battery tray as a unit. Ensure that the battery positive and negative terminal posts are correctly positioned. The battery cable terminal clamps must reach the correct battery terminal post without stretching the cables (Fig. 21).

Fig. 21 Battery Cables

1 - RADIATOR CROSSMEMBER
2 - WHEELHOUSE INNER PANEL
3 - NEGATIVE CABLE
4 - POSITIVE CABLE
5 - BATTERY

(4) Reinstall the battery hold downs onto the battery.

Refer to Battery Hold Downs in the index of this service manual for the location of the proper battery hold down installation procedures.

CAUTION: Be certain that the battery cable terminal clamps are connected to the correct battery terminal posts. Reversed battery polarity may damage electrical components of the vehicle.

(5) Clean the battery cable terminal clamps and the battery terminal posts. Refer to Battery in the index of this service manual for the location of the proper battery cleaning and inspection procedures.

(6) Reconnect the battery positive cable terminal clamp to the battery positive terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

(7) Reconnect the battery negative cable terminal clamp to the battery negative terminal post. Tighten the terminal clamp pinch-bolt hex nut to 8.4 N·m (75 in. lbs.).

(8) Apply a thin coating of petroleum jelly or chassis grease to the exposed surfaces of the battery cable terminal clamps and the battery terminal posts.

Battery thermoguard

REMOVAL

(1) Remove the battery and the battery thermoguard from the battery tray as a unit. Refer to Battery in the index of this service manual for the location of the proper battery removal procedures.

(2) Carefully and evenly slide the battery thermoguard up off of the battery case (Fig. 22).

Fig. 22 Battery Thermoguard Remove/Install

1 - THERMOGUARD
2 - BATTERY

INSTALLATION

(1) Clean and inspect the battery thermoguard.

Refer to Battery in the index of this service manual for the location of the proper battery thermoguard cleaning and inspection procedures.

(2) Carefully and evenly slide the battery thermoguard down over the battery case.

(3) Install the battery and the battery thermoguard into the battery tray as a unit. Refer to Battery in the index of this service manual for the location of the proper battery installation procedures.

Battery tray

REMOVAL

(1) Remove the battery from the battery tray.

Refer to Battery in the index of this service manual for the location of the proper battery removal procedures.

(2) Remove the battery temperature sensor from the battery tray. Refer to Battery Temperature Sensor in the index of this service manual for the location of the proper battery temperature sensor removal procedures.

(3) Remove the three nuts with washers that secure the battery tray to the weld studs on the front extension of the right front wheelhouse inner panel (Fig. 23).

Fig. 23 Battery Tray Remove/Install

1 - TRAY
2 - NUT AND WASHER (3)
3 - T-BOLT (2)
4 - RETAINER (2)
5 - WELD STUD (3)

(4) Remove the battery tray from the weld studs on the front extension of the right front wheelhouse inner panel.

(5) From the top of the battery tray, remove the plastic push-on retainers from the T-bolts that secure them to the tray.

(6) From the bottom of the battery tray, remove the two T-bolts from the T-bolt mounts on the tray.

INSTALLATION

(1) Clean and inspect the battery tray. Refer to Battery in the index of this service manual for the location of the proper battery tray cleaning and inspection procedures.

(2) From the bottom of the battery tray, position the two T-bolts into the T-bolt mounts on the tray.

(3) From the top of the battery tray, install the plastic push-on retainers onto the T-bolts to secure them to the tray.

(4) Position the battery tray onto the weld studs on the front extension of the right front wheelhouse inner panel.

(5) Install and tighten the three nuts with washers that secure the battery tray to the weld studs on the front extension of the right front wheelhouse inner panel. Tighten the nuts to 5 N·m (45 in. lbs.).

(6) Install the battery temperature sensor onto the battery tray. Refer to Battery Temperature Sensor in the index of this service manual for the location of the proper battery temperature sensor installation procedures.

(7) Install the battery onto the battery tray. Refer to Battery in the index of this service manual for the location of the proper battery installation procedures.